Slug casting apparatus and method



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J. H. FRIDN SLUGCASTING APPARATUS AND METHOD 11 Sheets-Sheet 5 fgwvemroz:

1l8- 4, 1942) J. H. FRIDEN l 2,292,266

SLUG CASTING APPARATUS AND METHOD Filed Aug'. 2, 1940 11 sheets-sheet e Aug. 4, 1942. J. H. FRIDEN SLUG CASTING APPARATUS AND METHOD l1 Sheets-Sheet 7 Filed Aug. 2, 1940 Aug. 4, 1942. J. H. FRIDEN 2,292,256

SLUG' CASTING' APPARATUS AND METHOD.

:Filed Aug. 2, 1940 11 'sheetsfsneetfs rci- RNEY Aug- 4,1942- v J. H. FRIDN 2,292,266

SLUG CASTING APPARATUS AND METHOD Filed Aug. 2, 1940 11 sheets-sheet 9 lNvENToR':

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Aug. 4, 1942. J. H. FRIDN SLUG CASTING APPARATUS AND METHOD Filed Aug'. 2, 1940 ||||||1||| .llllltllvrrmlrL/Llllll IIIANVIII ATTORN EY Aug. 4, 1942. J. H. FRIDEN v 2,292,266

SLUG CASTING APPARATUS AND METHOD y Filed Aug. 2, 1940 11 sheets-shee3e` 11 Patented -ug. 4;, 1942 s PATENT oFFlcE azsazeo SLUG CASTING APPARATUS AND METHOD .lohn 1I. Frldn, Maplewood, N. J., assignor to `The Sun Tube Corporation, Hillside, N. J., a corporation ot New Jersey Application August 2, 1940, Serial No.v 349,849

17 Claims.

This'invention relates to improvements in apparatus i'or and methods of producing slugs ofA the type employed for the exrusion oi shells, cups or containers of various sorts. More particularly it has reference toapparatus and methods by which slugs oi this character may be cast as individual units.

Heretofore it has been the common practice to produce slugs for the extrusion or tin containers, zinc cups and the like by stamping discs of the appropriate size from sheets of material having the thickness of .the desired slugs. This method involves considerable waste, however, when, as is the common practice, the slugs are stamped from the sheets at the plant where the extrusion oi the slugs into lthe iinished article takes place. There is necessarily. a great deal of scrap left between'the openings from which v the slug discs have been stamped and this waste material, according to the usual practice, must be sold at a very low figure and returned to the concerns from whom the original iiat sheets are procured. This waste is eliminated through the present invention by the provision of a small unit adapted to cast the material into individual slugs of the desired shape and size. The relatively small vamount of scrap developed in the trimming oi' the extruded tubes or cups may be readily reused in the unit so that there is no loss by way of scrap.

A particular object of the invention has been to produce slugs of the character mentioned which are uniform in thickness and grain structure and are free from defectasuch as cracks, surface impurities and the like. `Toward'this end care is exercised.' in accordance with the invention. to prevent the inclusion of scalev and other dirt in the material from which the slugs are formed and to eliminate the inclusion of gas bubbles within the slugs as they solidify.

Another object of the invention has been to provide a continuously and automatically operating unit for the production of the individual slugs. The arrangement is such that the slugs are poured'and formed in a continuously moving series of molds and are discharged from the molds when thoroughly solided.

A speciall feature of the invention sion of means for accurately measuring the molten metal discharged into the molds for the formation of each of the slugs.

The invention is particularly adapted for the production of zinc slugs employed in the extrusion of cups for dry batteries. Various special features are provided to enable the continuous is the proviformation of slugs of this character having the desired uniformity and perfection. However, the invention is also applicable to the production of slugs of tin, lead, aluminum and similar metals.-

Moreover, certain phases of the invention are appiicable to the production oi articles other than individual slugs. For example, slabs may be cast and these may be subsequently rolled and punched to produce slugs, or bars constituting a` multiple of slugs may be formed. Articles of any. appropriate shape might, in fact, be produced.

Other objects and advantages of the invention will appear from the detailed description of an illustrative form of the same which will now be given in conjunction with the accompanying drawings. in which:

Figure 1 is a front elevational view of a iurnace and slug casting unit constructed in accordance with the invention. l

Figure 2 is a top plan view lof the apparatus.

. Figure3 is 'a vertical section. on an enlarged scale taken along the line 3-3 of Figure 2..

Figure 4 is an enlarged detail in section through a safety valve employed in the apparatus.

Figure 5 is a rear elevation of 'a portion ci the I apparatus disclosing particularly the operating means for the metal pouring and measuring devices.

Figure taken along the line 5ft-5a of Figure 5.

Figure 6 is a transverse sectional view, on an enlarged scale, through the auxiliary chamber and the measuring and pouring devices illustrated in Figure 5.

Figure 7 is a detail view in horizontal section along the line 1-1 of Figure 6.

Figure 8 is a detail view in vertical section along the line 8-8 of Figure 6.

Figure 9 is an elevational view of a plunger used in the measuring device.

Figure l0 is a cross-sectional view of the plunger along the line Ill--Ill o'r Figure 9.

Figure 11 is av longitudinal, sectional view through a sleeve in which the plunger is oper-y ated.

Figure 12 is a plan view, partly in section, i1-

lustrating certain of the operating and control tion, along the line Il--Itof Figure 13,. illustrat-` ing certain oi .the operating devices for the meas- 5A is 4a detail view in section of a portion of the devices illustrated in Figure 5 and is uring and pouring means, a safety releaselin a connection provided between two levers-being illustrated in section within the circle on a magnified scale.

Figure isv a vertical section on the same line as Figure 14) but in the direction of the arrows Figure 16 is an enlarged detail view, partly in plan and partly in horizontal section, illustrating particularly a portion of the` driving means for the mold-carrying conveyor.

Figure 17 is a fragmentary elevational view taken along the line I1-I'l of Figure 16.

Figure 18 is a front elevational View, partly in section, of a portion of the mold-carrying conveyor, cooling trough and associated devices.

Figure 19 is a transverse vertical section, on an enlarged scale, along the line I9-I9 of Figure 18.

Figure 20 is a transverse vertical section, on a similarly enlarged scale, along the 'line 20-20 of Figure 18.

Figure 21 is an end view of a portion of the apparatus, showing in detail certain devices at the point where the slugs are discharged from the molds.

Figure 22 is avertical section along the line 22-22 of Figure 21, and

Figure 23 is a diagram indicating the relative timing o'f various operating devices embodied in the apparatus.

Furnace construction Referring now to the drawings, particularly Figures 1, 2 and 3, the furnace I,` for melting and retaining the metal from which the slugs are to be cast, is preferably of substantially cubical form. It may be of any suitable material but preferably is of refractory material, such as re,

brick. While only a single slug-producing unit is shown in association with the furnace I, its construction is such as to readily enable a plurality of slug-producing units to be associated with corresponding flange of the lire pot. Within the annular chamber of the fire pot, and between the walls of the same and the walls of the crucible, there is provided a mass o1' fusible metal 8, such as lead. This metal should have 'a lower melting point than that of the metal from which the vslugs are formed, the latter being placed in the heating of all or a portion of the metal in the it. For example, two of these units might bedisposed on opposite sidesof the furnace or a unitmight be disposed on each of the four sides of the furnace, if desired.

Heat may be supplied to the furnace in any convenient way, an oil burner 2 being illustrated for this purpose. Preferably the inner wall of the furnace is of cylindrical form and around the top of the cylinder' opening there is provided a Iring 3, preferably formed of iron or steel. This ring is` adapted to support a re pot 4, which is preferably also formed of metal, such as iron or steel. As shown, the fire pot may be in the form of a truncated cone open at its base, which faces upwardly. An annular flange, extending laterally from the' open base, serves to support the fire Apot from the ring 3. At the center of ,the re pot there is formed a ue 5 in the form of a truncated cone, communicating at its smaller, upper end with a stack 6 adapted to carry off the products of combustion from the furnace I. portion 5, the fire pot 'forms an annular chamber adapted to receive a crucible 1, preferably formed of some suitable refractory material capable of being molded into the desired shape. This crucible is of a shape similar to the -fire pot but it is somewhat smaller in its outer dimension and has its hollow, central, upstanding portion surrounding, but spaced from, the flue .5 of the fire pot. A laterally extending flange, around the Between its outer wall and the flue top of the crucible, serves to support it from the crucible is avoided.

Metal transferring means At one side of thefurnace I there is provided an auxiliary chamber or pot 9 adapted to retain a small quantity Iof the molten metal and from which the metal to form the slugs is poured or pumped in measured quantities. The metal is transferred from the-crucible l to the auxiliary chamber or p ot 9 by a syphon, formed preferably of silica or other refractory material, having a vertical leg I0 and a downwardly sloping portion II terminating in a vertical extension I2. The leg Il) is adapted to extend into the crucible l to a point well below the surface of the molten metal therein and it extends upwardly a considerable distance. above the point at which the downwardly sloping portion II branches oiI. The vertical extension I2 is disposed within the auxiliary chamber 9 and extends to a point-well below the surface of the molten metal therein, when the apparatus is in normal operation.

The upper end of the leg I0 of the syphon is reduced in diameter and connected by means of a tube or hose I3 and a pipe I4 with a T fitting I5 having one branch comunicating with a vacuum tank Il and its other branch communicating with a vacuum gauge I8. It will be understood that a vacuum .pump (not shown), of any suitable construction, ,is connected with the vacuum tank Il tomaintain any desired degree of vacuum therein. Such a pump may be connected with the tank through a line I9 having interposed therein a vfilter 20.

By means to -be later described, the molten metal delivered by the Syphon to the auxiliary chamber 9 is in turn delivered from the latter in measured quantities to suitable molds. The syphon serves to maintain a constant supply of the molten metal in the auxiliary chamber and thus insures the proper delivery of the metal to the molds. To start the syphon, the lower end of the extension I2 may be closed off in any suitable way or a small amount of the metal may be transferred by a suitable dipper or ladle from the crucible 'I to the auxiliary chamber. When the vacuum tank I`| is `then made effective upon the syphon, it will permit the atmospheric pressure to force the molten; metal to a suitable height in the leg I0 above the point where the portion II branchesol. The length of the leg Il) and the degree of vacuum employed should be such in relation to lthe specific weight of the molten metal that there is no danger of forcing the metal into the tube I3 and into the vacuum tank l1. Preferably, the extent of the vacuum is such as to' draw the metal merely to a point well below the top of the leg I0 of the syphon, If desired, a safety valve I5 (Fig. v4) may be connected with the pipe I4 so that if the vacuum in the tank I'I exceeds the desired amount, air will be drawn into the pipe I4 through the safety valve. By appropriate adjustment of the thumbscrew, 'shown v safety valve will open may be varied.

It will be understood that as the metal is maintained by. the vacuum atan appropriate height in the leg |||of the syphon,v above the point oi' juncture between this leg and the portion the syphonwill tend to maintain the metal in the erucible 1 and in the auxiliary chamber 9 at substantially the same level. Accordingly, suiiicient metal for this purpose will be transferred initially and as metal lis withdrawn from the chamber 9, it will be replaced by a iiow of the metal from the crucible 1.

Any appropriate means maybe provided for supporting the syphon. As best indicated in Figure 3, this may comprise a bracket 2| having a vertical portion paralleling theleg I of the syphon and another portion paralleling the hub part of the syphon. The bracket may be provided with a suitable base 22' bolted or otherwise secured to the flange of the crucible 1. Clamps or straps 2|a may be employed for retaining the syphon in the appropriate position on the bracket.

The downward slope of the portion of the syphon aids in the proper removal of any air,

or gas bubbles which may be entrapped in the molten metal and which, if not removed, might produce a defective slug. This removal of occluded gases is important since the presence of a small bubble in a slug is likely to produceA a pinhole in the extruded cup or tube. In the use of the syphon any air or gas bubbles in the metal will readily rise and move along the upper surface of the sloping portion of the syphon and vhence up the vertical leg |ll to the vacuum tank. The parts ||i,r|| and I2 of the syphon are preferably only about one inch in diameter, due to 'practical considerations, and it is this relatively small gauge of the tubing that creates difculty in the removal of air or gas bubbles and makes it important to have the shape of the syphon such as to impose as small an obstacle to the movement of the gas bubbles as possible.

Means are preferably provided for either indicating or recording the temperature of the metal in the crucible 1. For this purpose a pyrometer "23, of any suitable construction, may be employed, this being connected with a suitable gauge 24 which will visually indicate the temperature of the metal. If zinc is being used in the pro- S duction of the slugs, its meltingpoint 1s about 787 F. and, therefore, the molten metal being syphoned may range from 850 F. to 950 F.

Means are'provided for supplying heat to the syphon to prevent the cooling of the metal in transit from the crucible to the auxiliary chamber 9. For this purpose a burner 25 of suitable construction may be employed. This burner is preferably formed with two legs adapted to parallel the vertical leg I0 and the inclined portion together with a part'of the vertical leg l2 of l the syphon. Suitable ,apertures are provided in the side of the burner facing the syphon so that a series of flames may be directed against the syphon over the major portion through which the molten metal flows. For the operation of the burner, gas or a mixture of gas and air may be led through a pipe 26 and a branch line 21 (Fig.

3), the latter communicating with the top of Valves 28 and 29 may be em the burner. ployed in the branch 21 and line 26, respectively, for regulating the flow. The burner may be re- .y 2,292,266 in rig. 4, the point at which the e Figure 2, this phon by means of one of the clamps 2|a. Casting unit frame construction Turning now to the casting machine unit, only` one ot which-is associated with the furnace in isv supported by a main frame preferably formed of a series of angle members. A pair of longitudinally extending angle members 3|, disposed at a convenient level above the floor and a similar pair the angle members 3|, are supported and connected by means of aseries of vertically disposed angle members 33, one at each corner of the frame. To permit the height of the frame to be adjusted, and to enable the leveling of the frameJ it is supported by a series of four adjustable bolts 34, which are loosely mounted at their lower'ends in lsockets in a series of blocks 35 serving .as'feet adapted to rest on the floor. vThese bolts are threaded through blocks carried by the angle' members 32 and are provided with lock nuts beneath these blocks. The bolts are simply turned to effect the adjustment indicated, l

and. the lock nuts are then tightened. A series of f; transversely extending angle members 33, supported by the angle members 3|, serve to complete the main frame and provide a rigid support for the unit as a whole. Above the longitudinal angle members 3| there is another pair of similar angle members 31 parallel with' the members 3| but positioned more closely together. One of the members 31 is secured to and supported by a pair of the vertical members 33 while the other member 31 is carried by brackets 38 secured` to `the transverse members 36. Also, above oneof the angle members 3| is a flat bar 39 extending longitudinally of the frame and secured thereto in appropriately spaced relation by means of a number of C brackets 40.

A pair of fiat bars 4| is disposed transversely across the angle members 31 and is bolted thereto '(as best shown in Fig. 19). These transversely extending bars are arranged to support an elongated tank or trough which extends longitudinally of the unit for the major portion of its length. This tank is formed by a pair of side plates 42 and 43, a bottom plate 44 and end plates 45 and 46, all Aunited in an appropriate manner to provide a water-tight reservoir. At an intermediate point (as best shown in Fig. 19) the tank is `enlarged in cross section by the introduction of a box-like member -41 in lieu of a portion of the bottom plate 44. The box 41 may be secured to the plates 42 and 43 by welding, or other suitablevmeans, and is arranged to form a water-tight connection with the latter as well as with the abutting ends of the bottom plate 44. At its top the boxv 41 is partially closed by al channel 48 extending longitudinally along theouter face of the plate .43. An open- Mold conveyor Two C brackets 50, secured to the bars 4|, carry longitudinally extending angle member 5| and bar 52 which assist in guiding and retaining a mold conveyor, which will nowbe described. The molds 53, into which the molten metal is poured to produce the slugs, are 'best shown in Figs. 2, 18, 19 and 20. Each mold is tained in proper position in relation to the syof angle members 32 below carried by aplate 54 adapted to be supported by,

and to slide along, the upper edges of theV plates' 42 and 43 during a portion of its travel. An angle member 55 extending longitudinally of the plate 42 and secured thereto, withv its horizontal leg spaced slightly above the upper edge of the plate, serves to retain and guide one end of each of the mold-supporting plates 54 while the opposite ends of the plates 54 are guided and held in place by the angle member 5| and the bar 52. T'he plates 54 are connected together by an endless conveyor chain through which the molds are shifted along a predetermined path. For this purpose, there is secured beneath each plate 54 a pair of angle brackets 56 between which is journaled a small roller 51. The pins carrying the rollers 51 are connected by a series of links 58 (best shown in Fig. 17) forming a continuous chain which passes around a pair of sprocket wheels 59 and 60 adjacent the opposite ends of the main frame. The sprocket 59, which is driven, is carried by a shaft 6| journaled in bearing blocks 62 and 63 secured to the angle members 31 while the sprocket 60 is carried by a shaft 64 journaled in bearings 65 secured to the angle members 31.

As best shown in Figures 1 and 18, the shafts Gland 64 are so positioned in relation to other supportingV and guiding means for the conveyor that the mold-carrying plates are brought somewhat higher in their travel around the end sprockets than at intermediate portions of their travel. The bar 52 (as shown in Fig. 18) is suitably bent upwardlyat its two ends to direct the plates downwardly from the sprocket 59 to the main plane of travel of the upper course of the conveyor and upwardly adjacent the opposite end toward the top of sprocket 68. This arrangement is such that the molds are carried into the elongated tank over the top of the end plate 45 vand are then carried through the major portion of the length of the tank with their bottom portions immersed beneath the surface of the water carried by the tank. As the molds approach the opposite end of the tank they y will again be raised to clear'the end plate 46.

Water is introduced into the elongated tank through an inlet 66 (Figs. 1 and 18), connected in any suitable way with a source of water supply. Preferably the water will be admitted continuously during the operation of the unit. Adjacent the opposite end of the tank an adjustable dam 61 may be employed, this dam being raised to an appropriate height to maintain a desired water level within the tank. As the water is continuously admitted into the tank, the surplus flows over the dam into a small compartment 68 at the end of the tank, from which it is withdrawn by an overflow pipe 69 Conveyor drive Themeans for continuously driving the mold conveyor may comprise a motor 10 (Fig. l) which, as will be later explained, supplies the motive power for all of the operating portions,

of the-machine. This motor is connected by a belt 1| with a speed-reducingmechanism 12 of any suitable character; it may be a variable speed reducer so that the operation of the machine may be regulated as desired.- The opposite end of the speed reducer is connected by a chain 13 with a sprocket 14 (Eigs. 12`and 13) secured to the shaft 6|. A jack shaft15, journaled in the same bearing blocks 62 and 63 which carry the shaft 6|, is driven from the latter through a pinion 16 secured to shaft 6I and a gear l1 secured to the jack shaft. At the opposite end of the jack shaft a pinion 18 is secured and this meshes with a gear 19 keyed to a sleeve 8u rotatablymounted on the shaft 6|. It will be seen that through the connections indicated, the sleeve 8u will be driven by the shaft 6| but at a redied speed.

The sprocket 59, which drives the conveyor chain, is mounted loosely upon the Asleev'e 80. It is driven, however, by the sleeve 89 at the speed of rotation of this sleeve. For this purpose an arm 8| (Figs. 12, 13, 16 and 17) is keyed to the sleeve, this arm being adjustably connected with the sprocket 59, in the manner now to be explained. A swiveled stud 82 is carried lby the end of the arm 8| and another swiveled stud 83 is carried by the sprocket wheel 59. A bolt 84 p-asses freely through the stud 82 and is threaded in the stud 83. The stud 82 'is clamped between the head 85 of the bolt and a collar 86 pinned or otherwise secured to the bolt. It will be-apparent that upon rotation of the bolt the stud 83 will be brought. closer to the ystud 82 or will be forced further away from the latter, depending upon the direction of adjustment of the bolt. This will in turn cause an adjustment of the sprocket wheel 59 with respect to the driving mechanism. The purpose of this adjustable connection, as will be made apparent later, is to enable the proper positioning of the molds on the conveyor in relation to the means for supplying measured quantities of molten metal to the molds as they move through a particular zone.

To enable the conveyor and molds to be shifted manually whenever desired, as at the commencement of the operation of the unit, the shaft 6| `is provided with a reduced portion 81 (Fig. 12)

which is preferably square in cross-section and adapted to receive a handle 88 indicated in dot and dash lines in Fig. 2.

Metal measuring and pouring means Returning now to the auxiliary chamber 9, from which the molten metal is supplied to the molds of the conveyor, this chamber, as best shown in Figs. 6 and 8, is carried by a casting 89. A plurality of ribs or cross-bars 90, integral with the casting, provide a supporting surface for the base of the auxiliary` chamber, these ribs having upstanding lugs at their ends cooperating with the sides of the chamber to asist in positioning it. Clamping members 9|, attached to the casting 89 by means of bolts 92, may be provided for securing the chamber to the casting. A plate 93, attached to the bottom of the casting, has a downwardly extending sleeve adapted to surround the upper end of a vertical shaft 94 to which the lsleeve is pinned. The shaft 94 is journaled in will serve to raise or lower the shaft 94 and the vconnected auxiliary chamber.

As will be explained later, the chamber may be oscillated in the course of operation of the machine so that a spout portion t@ of the chamber (Figs. 2 and 6) may follow the movement of a mold on the conveyor as metal is being discharged into it. The I plates 5d of the conveyor, only a slight clearance being provided between the mold-carrying plates and the underside of the spout. In line with the spout there is an inward propection it into the interior of the chamber S, this projection terminating some distance below the top edge of the chamber. An inclined passage of suitable diameter to permit the free flow of the molten metal, is provided from the inner end of the projection |00 to the outer end of the spout 99. This passage is inclined upwardly from its inner to its outer end at an angle of about 30 to the horizontal. A cylindrical opening |02 extends vertically through the spout 99 adjacent its outer end, this opening intersecting the pasage |0| and being so disposed as to communicate with the centers of the molds on the conveyor as they pass beneath the spout.

lA projection |00 is provided with a cylindrical well w3 adapted to receive a sleeve |04. This sleeve, preferably formed of some suitable refractory material, has an opening communicating with the upper side of the passage |0| and a similar opening |06 communicating with the lower side of this passage, which in turn communicates with the main body of metal in the chamber 9. A plunger |01, formed of some suitable refractory material similar to thatv of which the sleeve |04 is formed, is adapted to be, both reciprocated and oscillated within the sleeve. The lower portion of the plunger has only a slight clearance, suiilcient to provide a good working t with the sleeve, while the upper portion of the plunger is of reduced diameter to minimize the friction with the sleeve.A A groove |08 extending upwardly from the lower end of the plunger to a point above the passage |0| communicates with the latter through the opening |05 in the sleeve when the plunger is rotated to the proper position. Similarly, a groove |09 extending upwardly from the bottom of the plunger |01 is adapted to communicate with the opening |06 in the sleeve and the lower portion of the passage |0| when the plunger is rotated into the proper position for this purpose.

As best indicated in Fig. 7 the grooves |08 and |09 are located about 120 apart. In the operation of the plunger one or the other of these grooves will be placed in communication with the passage |0I. Means, which will be described, are provided for reciprocating and oscillating the plunger in such a way that, as the plunger rises it will be turned into a position in which the groove |09 communicates with the lower portion of the passage 0|, thereby admitting molten metal beneath the plunger. At the same time the groove |08 is preferably carried out of communication with the upper portion of the passage I0 f Before the plunger commences its downward movement, it is rotated to carry the groove |09 out of communication with the opening |06 and to carry the groove |08 into communication with the opening |05. The plunger is then moved downwardly and the molten metal beneath it is forced upwardly through the groove |08 and through the' passage |0| over the lip formed between this passage and the opening |02. A measured quantity of the metal, determined by the stroke oi the plunger, will thus be discharged through the opening |02 into the mold which at that moment happens to be beneath the opening |02.

The plunger and the sleeve |04, or at least one of them, may be formed of a graphite com position. This material is capable of. withstanding-the heat of the molten metal, will not react with zinc or the like and has other characteristics which render it suitable for the purpose. It appears to have a self -lubricating action in the reciprocation and oscillation of the plunger. If desired the sleeve and plunger may be formed of substantially pure tungsten, which has all of the. required properties but is almost prohibitively expensive. To minimize the expense the sleeve may be formed from soapstone and then red at a suitable temperature. The resulting product has the desired characteristics'and works well with a tungsten plunger. The graphitel composition, while inexpensive. does not have good Wear-resisting qualities and, therefore, if it is used, the plunger and sleeve must be replaced rather frequently. For this reason vthe means for operating the plunger should be so constructed as to enable the plunger and the sleeve |04 to be replaced with a minimum of time and eiort. These operating means, furthermore, should be readily adjustable as to stroke to allow for wear of the parts and also to enable the delivery of variable amounts of metal for slugs of diierent weights. i

Preferably the plunger is built around a metal core ||0 (Fig. 9) which extends above the refractory material. The upper end of the plunger is adapted to be received and operated by a socket member In the preferred construction the upper end of the plunger |01 is adapted to be simply inserted in and frictionallyretained by a split collar` ||2 (Figs- 5A, 6 and 8) inserted in an opening ||3 in the bottom of the member I. Set-screws I4, passing through the wall of the member into the opening in its ,lower end, are'adapted torengage the split collar to retain it and urge it under the proper tension against the inserted plunger. communicating with the opening H3, is adapted .to receive the extension ||0 of the metal core lars'llS are provided on therod ||8 at opposite sides of the arm ||1 and a nut |20, threaded to the lower end of the rod, serves to hold the parts together. The rod ||8 is slidably mounted in appropriate bearings carried by a sleeve |2|, preferably formed integral with a bar |22.`

The latter is bolted or otherwise secured to the upper ends of a pair of brackets |23 and |24 attached to one of the angle members 31 of the main frame structure.

`'I'he rod ||8 is straddled by the forked end |25 of one arm |26 of a bell crank pivotally mounted on a pin |21, extending from the bracket- |23. Arm |26 is adapted to actuate the rod I8 longitudinallyby virtue oi the engagement o1' the forked end between the upper. collar IIS and An aperture H5,

ing arm |25 of the bell crank is connected by means of a link 29 with a lever |50 pivotally `mounted upon the jack shaft l5. 'Lever |90 has the plunger, is made variable by adjusting the position oi the end of the link |29 with respect to the arm |28 of the bell crank. For this purpose the arm |28 ls provided with an elongated slot in which a bolt |33 may be shifted to any desired position and then tightened to clamp a yoke |35 at the end of the link H29. Similarly, at its opposite end the link |29 is provided with a block |35 adjustable in an elongated slot in the lever |30 and adapted to be locked in any position of adjustment in said slot.

The link |29 is preferably formedin two parts, a rod |31 and a sleeve |38, which are in telescoping relation. The sleeve S5238 has a downwardly extending cylinder |39 in which there is mounted a ball |60 urged into a groove ME, in the rod |31, by means of a spring |52. This construction is shown on a magnified scale within the circle in Fig. lli. A plug M3 serves to retain the spring in the cylinder and provides a means of adjusting the tension of the spring. it will be apparent that this type of connection is releasable so that if there is excessive resistance to the movement of the plunger and its connected parts, the rod |31 will simply slide in the sleeve |38, urging the ball |00 outwardly against the action ofthe spring.

oscillatory movement is imparted to the plunger by means similar to that provided for its reciprocation. (See Figs. 5, 5A, 12, 13 and l5.) i lever |44 pivoted at |55 upon a bracket |24a carries a roller |56 at its lower end adapted to engage the periphery of a cam |51 secured to the shaft 5|. A spring |48 urges the lever in a counter-clockwise direction (Figs. 5 and l5) for this purpose. At its upper end the lever is connected by a link |59 with an arm H50 extending laterally from a sleeve |5| 'rotatably mounted on the rod ||3 between the collar |25a and another collar |251). The link |69 is preferably of a releasable type similar to the link |29. An-

other arm |52, extending laterally from the sleeve |5| in a direction at about 90 to that of the arm |50, is connected by a link |59 with an arm |54 integral with the collar |||b` secured to the upper end of the extension |||a of the member The timing of the cams |32 and M1 is such as to bring about the ,previously explained movements of the plunger. This timing is indicated in the chart of Fig. 23. During the rst 1404 of the cycle indicated in the chart, the plunger is moved downwardly, causing the metal to be pumped and discharged into the mold which happens at the moment to be beneath the opening |02. At the beginning of this part of the cycle, the groove |09 will be in its closed position, i. e., out of register with the opening |06 in the sleeve.

, The groove |08, on the other hand, will at this time be :partly registered with the opening |05,

as indicated in Fig. '1. The outlet is fully opened 15 aaaaaee during the nrst 25 of the cycle and remains in this condition for the next while the inlet remains closed throughout both of theser periods. Following this the plunger is rotated in the op.- posite direction to partly and then fully close theioutlet and to iinally open the inlet. 'The inlet, however, does not open until after the ldownward movement of the plunger has ceased and it is not fullyopened until about the 200 point in the cycle.

Following the initial portion of the cycle, the plunger is moved upwardly under the action of the spring |33, as permitted by cam |32. This upward movement extends over about a 200 por-l tion of the cycle. For approximately 20 of this upward movement of the plunger, the outlet remains partly open and, therefore, a slight suckback action takes place which insures -a relatively sharp cutting off of the flow of metal and while the plunger is still moving upward, it y is oscillated back toward the position in which the inlet is closed and the outlet is partially opened. By the time the outlet commences to open, the plunger has stopped its upward movement and is being held stationary by a slight 20 dwell in the cam |32. The same cycle is then ready to be repeated.

Auxiliary heating means Means are provided forheating the metal in the auxiliary chamber so as to maintain it in the proper molten state until it is actually deposited -in the molds. For this purpose, a ilexible hose, or similar connection, |56 ,is provided from the top of the gas line 2B (Figs. 1 and 2) above the point at which the branch line 21 is taken oi. This nexible hose is attached at its other end to a burner element |51, which is inserted in a passage in the bottom of the member 89 and is retained therein by a set-screw |58.

At the top of the burner |51 there is an opening |59 which communicates With a. tube or pipe |60. The pipe |60 extends upwardly along the side of the auxiliary"chamber and over the top of the chamber and is provided with a burner element I6! at its free end directly over the passage |02 in the spout portion 99 of the chamber. (See Fig. 6.) A flame is thus discharged downwardly through the passage |02 at all times to insure maintenance of the proper molten state of the metal until it reaches the molds. The hot gases developed by the burner |51 follow the courses indicated by the arrows in Fig. 8. These gases in rising around the auxiliary chamber are conned between the latter and an4 outer casing or shell |62 which directs the gases inwardly at vthe top of the chamber and then permits their free discharge into the atmosphere.

Spout oscillating meansA Means may be provided for rocking the auxopposite end to aflever |66. This lever is piv-y otally supported at |61 on one of the angle memcidentally, the

I aaeaaee l bers 31 of the main frame and carries its i upper free end a roller |68 adapted to engage the periphery of a heart-shaped cam |68. A spring lli) serves to draw the lever in a clockwise direction (Fig. to engage the roller with the cam. It will be understood that the shape and timing of the cam/|69 is such that the passage |02 of the spout 99 will follow the movement of the mold that happens to be beneath it at the time the plunger |01 isdescending to pump and discharge a measured quantity of the metal. After the desired quantity of metal has been introduced into the mold, the spout will, of course, swing back to a position centrally over the next mold and will follow that in the same way during the next lling operation. Oscillation of the spout may be dispensed with, if desired, and the action of the pump so timed, that the metal will be discharged into each mold between the times that its leadin-g and following edges reach the pouring opening |82.

M old vibrating means To free any air'or gas bubbles from the metal and to cause it to spread out evenly over the A bottom o the mold, provision is made for vibrating the mold while the metal is being introduced into it and before it sclidifles. This vibrating means comprises a toothed wheel |1| (Fig. 1) secured to the shaft Si and cooperating with a roller |12 carried .by one end of a lever |13 pivoted at llt on a portion of the frame. Spring Iltends to rock the lever clockwise (Fig. l) and urges the roller |12 into engagement with the toothed wheel lll. At its opposite end the lever |13 isprovided with a hammer element |16, which is adapted to pass through an opening |11 provided in the bar 52 at a point substantially in line with the spout of the auxiliary chamber. It will be understood that as metal is being poured into one of the molds and for a short time thereafter, the hammer |16, which is being continuously vibrated by the toothed wheel |1| at a relatively rapid rate, will strike the supporting plate of the mold.

As the molds are carried around the sprocket 6|), the slugs, which will have been fully solidied by this time due to the cooling action of the water in the trough, are discharged. To assist in their discharge as the molds areturned on edge in passing around the sprocket, means are provided for vibrating or shaking the molds. For this purpose a supporting bar |18 (Fig. 2l) extends transversely across the tops of the angle members 31 adjacent one end and is suitably secured thereto. The bar extends beyond the angle member on the right (Fig. 21) and is apertured -to receive a bolt |19. vA spacer collar |88,

surrounding the bolt, supports, at its upper end,

one end of a lever I8! adapted to swing pivotally about the bolt |19. About midway of the length of the lever |8I, it carries a finger |82 having 4its end -slightly bent (as best shown in Fig. 22) This bent end of the finger cooperates edgewise with a ratchet wheel |83 secured to the shaft 64. As the latter rotates during the advance of the conveyor, the finger |82'will be cammed outwardly `until it reaches one ofthe shoulders provided by the teeth of the ratchet wheel and it will then move suddenly inwardly. A spring |84, connected with the lever |8| and with a portion of the frame, serves to hold the iinger |82 against the ratchet wheel and causes the latter to oscillate as the ratchet rotates. In-

shaft 84, to which the ratchet wheel is secured and which is carried by the bearings 65, is adjustable toprovide the desired which, upon each sudden inwardv movement ofA the lever as the finger |82 reaches the successive shoulders of the ratchet wheel, strikes the adjacent mold-supporting plate and causes it to vibratesulciently to release the slug as the mold is carried into a vertical position. As the slugs are so discharged they fall by gravity into a chute |88, from which they may be directed into a bucket or may be delivered to any other point. J

' Summary of operation Itis believed that the operation of the furnace and molding unit will be clear from the foregoing but abrief resum will-now be given:

Assuming that the furnace has been brought to the proper temperature, and the bodies of metal in the fire pot 4 and in the crucible'are in a molten state, the mechanism is set in operation, the syphon being subjected toa partial -vacuum and being started to maintain molten metal in the auxiliary chamber 9 at substantially the same lever as in the crucible 1. The conveyor is set in operation and the pump plunger is caused to reciprocate while the auxiliary chamber is rocked about its axis at the appropriate speed and in the correct timing to retain. the pouring passage |82 directly over one of the molds during the'downward movement of the plunger. A measured quantity of molten metal is thus introduced into a mold and the auxiliary chamber is then rocked back to its initial position, in which the pouring passage |02 is placed over the next succeeding mold and is caused to travel along with` this during the next downward movement of the plunger. Since the metal delivered to the m'olds is taken from a point well below the surface of the mass in crucible 1- and is also pumped from a point well below the surface of the metal in the auxiliary chamber, its purity andv cleanliness is insured.y It is quite free of the dirt, slag, scale, oxidized metal and other impurities which form on or rise to the surfacejin the crucible and auxiliary chamber.

As the metal is being poured into the molds and for a suitable period thereafter, the molds are` being carried alongr with their lower portions immersed in the water in the elongated trough. This causes the metal to quickly solidify and cool after it has been deposited in the molds. During the pouring operation and immediately subsequent thereto, the mold is vibrated by the operation of the hammer |16, thus insuring the release of any gas that might otherwise be retained and causing the surface of the metal to level on'. As the molds reach the end of the trough, the metal slugs are well solidifiedv and the molds are carried upwardly over the darn 61 and around the sprocket 60. Here the mold plates are subjected to further vibration by the hammer element I8] which causes the metal and for retaining a mass of molten metal,v

means for supporting a plurality of slug forming molds, means for delivering a measured quantity of molten metal from said retaining means to each of said molds successively, said delivering means comprising an auxiliary chamber, means for transferring metal from beneath the surface thereof in said retaining means to said auxiliary chamber and means for transferring measured quantities of said metal from beneath the surface thereof in the auxiliary chamber and While out of substantial contact. with air to said molds, means for cooling said molds, and means for discharging the solidiiied slugs from said molds.

.apparatus for casting slugs of the character described which comprises means for retaining a mass of molten metal, means for supporting a plurality of slug forming molds, means for deliv- @ring a measured quantity of molten metal from said retaining means to each of said molds successively, means for shifting said molds and said delivering means in unison as the metal is being delivered tc one of the molds and relative to each other at other times, means for vibrating said a mass of molten metal, means for supporting a plurality of slug forming molds, means for delivering a measured quantity of molten metal from said retaining means to each of said molds successively, said delivering means comprising an auxiliary chamber, means for transferring metal from beneath the surface thereof in said retaining means to said auxiliary chamber and means for transferring measured quantities of said metal from beneath the surface thereof inthe auxiliary chamber and out of substantial contact with air to said molds, means for supplying heat to said metal in said retaining means and auxiliary chamber, means for cooling said molds, and means for discharging the solidified slugs from said molds.

4. Apparatus for casting slugs of the character described which comprises means for retaining a mass of molten metal, auxiliary means for retaining a smaller mass of molten metal, means for delivering metal from said retaining means to said auxiliary means, a plurality of molds, means fordelivering the molten metal from said auxiliary means to said molds, means for rocking' said auxiliary means about an axis passing through the same as the metal is being delivered therefrom, and' means for heating said retaining means, auxiliary means, and said several delivering means.

5. Apparatus for casting slugs of the character described which comprises means for retaining a.

molds upon the delivery of molten metal thereto,

taining a smaller mass of molten metal, means for delivering metal from said retaining means to said auxiliary means and maintaining the metal at substantially the same level in said retaining and auxiliary means, a plurality of molds, means for delivering the molten metal `from said auxiliary means to said molds, and means for heating said retaining means and auxiliary. means.

6. Apparatus for casting slugs of the character described which comprises means for retaining a mass of moltenmetal, auxiliary means for constantly retaining a. substantially uniform smaller mass of molten metal, means for delivering metal from said retaining means to said auxiliary means as it is being discharged from the latter, a plurality of molds, means for delivering measured quantities of the molten metal from said auxiliary means to saidk molds, Vand means for heating said retaining means and auxiliary means.

7. In apparatus of the class described a chamber for retaining molten metal, a Well associated with said chamber and arranged to receive metal therefrom, means communicating with said well for transferring metal discharged therefrom, a plunger operable Within said well, and means for reciprocating and oscillating said plunger, said plunger having channels rendered effective and ineffective upon oscillation thereof to admit metal from said chamber to said Well and to enable the discharge of the same from said well upon the downward movement of the plunger.

8. in apparatus of the class described a chamber for retaining molten metal, a well associated with said chamber, the wall of said well having a passage communicating with said chamber to deliver molten metal therefrom to said Well, a refractory sleeve fitted snugly Within said Well, said sleeve having an aperture alined with said passage and also having a discharge aperture, a plunger formed of refractory material having a sliding fitwithin said sleeve, said plunger having channels therein adapted to be carried into and out of registry with said apertures upon oscillation of the plunger, and means for oscillating and reciprocating said plunger. 1

.9. ln apparatus of the class described a chamber for retaining molten metal, a well associated with said chamber, the Wall of said well having a passage communicating with said chamber to deliver molten metal therefrom to said well, a

refractory sleeve fitted snugly within said well,

said sleeve having an aperture alined with said passage and also having a discharge aperture, a plunger formed of refractory material having a sliding fit within said sleeve, said plunger having i channels therein adapted to be carried into and out of registry with' said apertures upon oscillation of the plunger, an operating memberarranged to be reciprocated and oscillated, and

readily detachable connections between said ,member and plunger for imparting the movements of said member to the plunger.

y 10. In apparatus of the class described a chamber for retaining molten metal, a well associated with said chamber, the wall of said Well having a passage communicating with said chamber to deliver' molten metal therefrom to said well, a refractory sleeve' fitted snugly within said well,

said sleeve having an aperture alined with said passage and also having a discharge aperture, a plunger formed of refractory material having a sliding fit within said sleeve, said plunger having of the class described a chamber for retaining molten metal, a pump associated with said chamber, said pump having a well arranged to receive molten metal from said chamber and having a plunger adapted to be reciprocated and oscillated within said well, said plunger being formed of refractory, self-lubricating material, means for automatically reciprocating and oscillating said plunger, and readily accessible means for varying the reciprocatory stroke o'f said plunger.

f 12. In apparatus of the class described a reservoir for molten metal, a well connected with said reservoir and adapted to`receive metal therefrom, a plunger arranged to nt said well and to be reciprocated and oscillated therein, oscillation of said plunger being arranged to control the delivery of metal to and its discharge from said well, a spout connected with said well and arranged to receive metal therefrom upon reciprocation of said plunger, means for reciprocating and' oscillating said plunger, a. mold arranged to receive metal discharged from said spout, and means synchronized with said reciprocating and oscillating means for shifting said mold and said spout in unison as metal is being discharged from said spout.

13. In apparatus of the class described a reservoir for molten metal, a well connected with said reservoir and arranged to receive metal therefrom, a plunger formed of refractory material fitting within said well, means 'for oscillating and reciprocating said plunger, operating means, and separate connections from said operating means eachf releasable under excessive load for operating said oscillating and reciprocating means.

14. In apparatus of the class describal a plurality of molds, each of said molds being carried by a plate, said plates connected to provide a continuous conveyor, means for shifting said conveyor, means for delivering measured quantities of molten material to said molds as they are in a predetermined zone, and means for striking said plates to vibrate the same while in said zone as the molten material is solidifying.

15. In apparatus of the class described a plu- I rality of molds, each of said molds being carried by a plate, said plates being connected to provide a continuous conveyor, means for shifting said conveyor, means for delivering measured quantil ties of molten material to said molds as they are in a predetermined zone, means for striking said plates to vibrate the same while in said zone as the molten material is solidifying, and means for striking said plates after the material has solidified in the molds carried thereby to loosen said material.

16. In apparatus of the classdescribed a reservoir for molten metal, an auxiliary chamber adjacent said reservoir, and means for continuously transferring molten metal from said reservoir to said chamber which comprises a syphon, said syphon having a pair of legs connected by a cross member, one of said legs extending a substantial distance above said cross member and means connected with the extension'of said leg for subjecting said syphon to a substantially fixed, partial vacuum.

17. A method of casting a series of similar articles which comprises melting the material to be cast in a crucible, transferring the molten material from a point beneath the surface thereof to a pouring vessel adapted to retain sufficient metal for a plurality of molds, constantly maintaining substantially the same amount of metal in said vessel, continuously advancing a series of molds l past the pouring outlet of said vessel, and intermittently discharging the molten material from.

a point beneath the surface thereof in said vessel as the molds are successively carried past the pouring outlet.

JOHN H. FRDN. 

